Axial-fan blower

ABSTRACT

An in-line blower having a housing with a substantially straight airflow path. A motor and fan are positioned within the airflow path, below the handle of the blower. A battery powers the motor, and is located below the housing so that the handle, motor and fan, and the battery are vertically aligned so the weight of the blower is aligned with the handle, and reduces moment forces acting thereon.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 62/132,018, filed on Mar. 12, 2015. The entire disclosure of the above application is incorporated herein by reference.

FIELD

The present disclosure relates to blowers, specifically axial-fan or in-line type blower designs.

BACKGROUND

Axial-fan or in-line type blowers are known in the prior art, and typically include a fan whose axis is aligned with the air outlet so that the airflow is not forced to undergo any significant turn or bend, thereby increasing airflow efficiencies.

An example of such a design is shows in U.S. Pub. No. 2012/0076672, which shows a blower having an air inlet opening 13, an axial blower or fan 6 and an outlet opening 15 that are, for the most part, linearly aligned so as to reduce any curves which may impede airflow. For cordless or battery powered blowers, the battery is often located at the rear of the blower where the air intake exists, and so this presents an issue since the battery must be moved so as not to obstruct the air intake.

Another example of an in-line blower is shown in US Pub. No. 2013/0239361, where the battery is not attached to the blower, but rather placed on a user's back. This design requires a harness to secure the battery to the user's back and requires an electrical cable which between the battery and blower, which can get tangled or otherwise impede the user's movement.

Yet another example is U.S. Pat. No. 4,884,314 where the batteries are integrally secured in the handle of the blower. This design has the disadvantage of not having a removable battery, which is desirable for charging and continuous use with multiple batteries.

Accordingly, there remains a need in the art for an in-line blower that is comfortable and easy to use.

SUMMARY

This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.

In one form, the present teachings provide a blower that includes an electric motor, a rotatable fan driven by the electric motor, a handle, a battery, and an airflow tube. The airflow tube is generally straight so that the airflow through the blower does not undergo any significant change in direction. Additionally, the handle, motor and fan are vertically aligned so that the center-of-gravity of the blower is below with the handle, reducing any moment forces on the user.

In another form, the blower includes a battery housing surrounding the battery to protect it from damage. The battery housing can be used to support the blower when placed on the ground or other surface, further protecting the blower housing from scuffing damage.

In yet another form, the battery housing can be secured to the blower housing at an angle so that it's resting position on the ground is identical to the in-use position so that a user can immediately use the blower when picked up without having to readjust his grip.

Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

DRAWINGS

The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.

FIG. 1 is a perspective view of an exemplary blower constructed in accordance with the teachings of the present disclosure;

FIG. 2 is a side elevation view in partial section of the blower of FIG. 1;

FIG. 2A is another side sectional view of the blower of FIG. 1;

FIG. 3 is a top view of the blower of FIG. 1;

FIG. 4 is a rear view of the blower of FIG. 1;

FIG. 5 is a schematic view of components of a blower;

FIG. 6 is a side view of the blower of FIG. 1 placed on a surface;

FIG. 7A shows the position of the blower of the present invention, while on the ground and held by a user;

FIGS. 7B-7D show the position of prior art blower while on the ground and held be a user; and

FIG. 8 is a side sectional view of an corded electric blower.

Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.

DETAILED DESCRIPTION

With reference to FIGS. 1, 2 and 2A of the drawings, a blower constructed in accordance with the teachings of the present disclosure is generally indicated by reference numeral 10. The blower includes blower housing 12, a handle 14 positioned above the housing 12, and an air intake grill 16 at the rear of the housing 12. The housing 12 surrounds an airflow tube 18 which directs the airflow through the blower. The airflow tube 18 has a first end or inlet end 18A (shown in FIG. 2A) at the rear of the blower and is covered by the air intake grill 16. The airflow tube 18 has a second end or exhaust end 18B at a front end through which air exits the blower (shown in FIG. 2). A battery housing 20 is attached to the bottom of the housing and holds a battery 22.

Referring now to FIG. 2A, the battery 22 is electrically connected to a motor 24, positioned inside the blower housing 12, to deliver energy to the motor and drive fan 25. The fan 25 pulls air in through the air intake grill 16, through the fan 25, around the motor 24 and out through the exhaust end 18B of the airflow tube 18. As shown, airflow tube 18 is a substantially uniform body and provides a linear air path along the longitudinal direction of the blower, generally defined by the x-axis. The motor 24 and fan 25 are positioned within the airflow tube 18 in the path of the airflow so that their axes are parallel to the longitudinal axis of the blower. The tube 18 can be formed from a single integral body, or may be formed from several parts that are combined to form the body.

The blower includes a variable speed trigger 26 having a logic level switch 27. The switch is connected to a PCB 29 and the trigger distance determines the level of output from the switch, for example OV-5V, that is then translated by the PCB 29 to output a corresponding voltage range to the motor 24, for example OV-20V, that varies the speed of the motor 24, and consequently, controls the air speed through the blower. A speed lock 28 can mechanically lock the trigger 26 at a set speed to relieve the user from continually holding the trigger 26 in position.

Referring to FIG. 2A, the motor 24 and fan 25 are placed in the housing 12 below the handle 14. Additionally, the battery 22 is placed generally below the motor 24 so that the heaviest components of the blower are vertically aligned and the center-of-gravity (CoG) (as shown in FIG. 2) of the blower is directly below the handle 14. Having the CoG aligned with the handle provides many advantages. First, when the blower is held at a user's side, the weight of the blower is in line with the user's arm so that there is no moment acting on the user's hand. In other words, the blower does not tend to tip forward or backward, and so the user does not have to exert any force to keep the blower level or otherwise in position.

Second, since the weight of the unit is centered at the handle, this also reduces the force required to turn the blower side-to-side (rotate about the y-axis), as illustrated in FIG. 3. And third, the battery 22 acts as a ballast helping to maintain the blower in position in both the lateral direction (as shown in FIG. 4) and longitudinal direction.

In reference to FIG. 5, additional benefits of the arrangement of the handle 14, fan 25, motor 24, and battery 22 are seen. In addition to having the component vertically aligned, it is desirable to have the fan 25 as close to the handle 14 as possible to reduce any moment forces that are produced by the air exiting the airflow tube 18 (eg. the blower would tend to want to go backward in the user's hand). So for example, arrangement A is preferable over arrangement B, because when the fan 25 is operating, the air blowing out of the airflow tube 18 creates a moment partially determined by the distance between the handle and the fan 25. The greater this distance, the larger the moment forces created, which must be opposed by the user to maintain the blower in position. The distance A is less than distance B, and so produces small forces on the handle 14. Additionally, these same forces make it more difficult to control the blower when rotating it about the y-axis (see FIG. 3).

Now referring to FIGS. 1 and 4, the battery housing 20 is molded from a durable plastic, for example glass-filled polypropylene, and attached to the housing 12 to support the blower when placed on the ground. The battery housing 20 is designed to withstand drops and endure daily wear and tear from being scraped and banged on the ground or other surface. The battery housing 20 includes a top wall, side walls, and a foot portion 30 that extends outwardly to provide a larger support surface for the blower.

Now referring to FIG. 6, it can be seen that the longitudinal axis of the blower housing 12 and the airflow tube 18, as identified by the x-axis, is at an angle Θ₁ relative to the ground surface 32 when the blower 10 is sitting on the ground. The angle Θ⁰ ₁ is between 3-10 degrees, and in a preferred embodiment is approximately 5.6 degrees. Also, the longitudinal axis of the handle, as identified by h, is at an angle Θ₂ relative to the longitudinal axis x of the blower housing. The angle Θ₂ is between 15 and 25 degrees, and in a preferred embodiment is 20.5 degrees.

The angle of the blower housing 12 and handle 14 are such that the blower 10 is automatically in an in-use position when picked up by a user. This can be seen in FIG. 7A, where the angle of the blower housing 12 and airflow tube 18 are substantially similar in the in-use position held by the user, and when on the ground. Contrast this with FIGS. 7B-7D, which show examples of prior art units, where the angles of the exhaust tube are significantly different when sitting on the ground compared to the in-use position in the user's hand. This requires the user to then readjust his grip to get the blower in the proper position.

An alternative embodiment of the blower is shown in FIG. 8 where similar components are labeled with the same reference number. Here the electric blower does not require a battery and can be powered by alternative means, such as a power cord (not shown) attached to an outlet.

Here, the motor 24 has been moved out of the airflow tube 18 and positioned below the housing 12. The motor 24 is secured within a motor housing 40 below the main housing 12, or alternatively, the motor housing 40 can be formed integrally and as part of main housing 12. The motor 24 has a drive shaft 42 that is connected to a first end of a belt-drive or pulley system 34. The pulley system 34 is enclosed in a transmission casing 44, with a drive belt 46 therein, that connects the drive shaft 42 of the motor with a drive shaft 48 of the fan 25. In this way, rotation of the motor drive shaft 42 is transferred to the fan 25. In a preferred embodiment, the ratio of the pulley system is 1:1, but it should be understood that other ratios can be utilized.

The removal of the motor 24 out of the airflow tube 18 allows a larger motor to be used, since it won't be limited by the diameter of the airflow tube 18. Using larger motors, while maintaining fan size, and/or tube dimensions allows an optimized design for maximum airflow efficiency. This design also maintains the weight balance of the previous embodiment with the motor 24 acting as a ballast, helping to stabilize the blower when in use, similar to that described in the previous embodiment.

The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure. 

1-15. (canceled)
 1. A blower comprising: a main housing having a front, back, top and bottom; an outlet tube extending from the front of the main housing; an air intake at the rear of the main housing; a handle at the top of the main housing; a battery housing at the bottom of the main housing, and a removable battery being held by the battery housing to power the blower; wherein the blower is supported by the battery housing when resting on a surface.
 2. The blower of claim 1, wherein the main housing includes a longitudinal axis extending through its center, and the longitudinal axis is at a non-parallel angle relative to the surface when the blower is resting on the surface.
 3. The blower of claim 1, further comprising a motor and a fan enclosed by the main housing.
 4. The blower of claim 3 wherein the battery housing is below the handle, such that the battery housing intersects a space defined by the area underneath the handle.
 5. The blower of claim 3, wherein a vertical plane through the blower intersects the handle, motor, fan and battery housing.
 6. The blower of claim 3, wherein the battery is position below the motor and fan.
 7. The blower of claim 1, wherein the battery housing includes a foot portion that extends outwardly from a bottom portion of the battery housing.
 8. A blower comprising: a main housing having a front, back, top and bottom; a motor and a fan enclosed by the main housing; an outlet tube extending from the front of the main housing and an air intake at the rear of the main housing whereby air is drawn into the main housing through the air intake and expelled from the main housing into the outlet tube; a handle at the top of the main housing; and a battery housing at the bottom of the main housing, wherein the blower is supported by the battery housing when resting on a surface.
 9. The blower of claim 8, wherein the handle, motor and battery are vertically aligned so that the center of gravity of the motor and center of gravity of the battery are underneath the handle.
 10. The blower of claim 8, wherein handle, fan and battery are vertically aligned so that the center of gravity of the fan and center of gravity of the battery are underneath the handle.
 11. The blower of claim 8, wherein the main housing includes a longitudinal axis extending through its center, and the longitudinal axis is at a non-parallel angle relative to the surface when the blower is resting on the surface.
 12. The blower of claim 8, wherein the battery housing includes a foot portion that extends outwardly from a bottom portion of the battery housing. 